BAFANG M510 (MM G522.250.C) Dealer Manual
6.1 Introduction
Product Model: MM G522.250.C
Identification: The product features unique identification markings on its housing, as depicted in the accompanying diagram.
Diagram Description: An illustration showing the motor housing with a label indicating the model number and other identification details.
Scope of Application: This motor is exclusively for electric-powered bicycles, specifically designed or licensed for pedelec use. It is suitable for mountain bikes. It is not intended for competition or other commercial purposes.
Note: The information on the label is crucial for product software updates and after-sales service. Please keep it safe.
6.2 Specifications
| Specification | Details |
|---|---|
| Motor Model | MM G522.250.C |
| Rated Power | 250 W |
| Rated Voltage | 36 / 43 / 48 V |
| Waterproof | IP65 |
| Certification | CE / ROHS / EN14766 |
| Outdoor Temperatures | -20 °C to 45 °C |
6.2.1 Outline and Geometric Size
Diagram Description: A technical drawing of the motor unit showing its outline and key geometric dimensions, including measurements like 127mm, 45.8°, 47.7°, 197mm, and 138.5°.
Chain line (CL): 53mm
Shaft standard: BAFANG
6.2.2 Surface
The motor features a shockproof black coating.
6.2.3 Storage Information
The pedelec unit should be stored in a ventilated, humid, and dry room. Avoid storing the unit near strong magnetic objects.
6.3 Drive Unit Installation
6.3.1 List of Tools to be Used
Important Note: Do not use impact wrenches.
| Use of the Tools | Tools Required |
|---|---|
| To fasten screws onto the frame interface and the drive unit | Internal hex wrench |
| To fasten screws on the crank | Internal hex wrench |
| To mount the bash guard and cover | T10 Torx screw driver |
| To fasten screws on the motor cover and cable cover | T10 Torx screw driver |
| To lock and loosen the lock nuts on the chain wheel | BAFANG tool |
| To fasten nuts onto the frame interface and the drive unit | Socket spanner (BAFANG: diameter=17.7mm, length=63mm; OTHER: diameter <20mm, length >35mm) |
| To connect the cabling | BAFANG tool |
6.3.2 Install Drive Unit to Connection Interface
Diagram Description: Illustrations showing the drive unit being mounted to the frame interface. Components are labeled: A (M8 bolt), B (M8 flat washer), C (M8 lock nut), D (Tool-socket spanner).
Steps:
- Align Hole 1 on the frame interface with the mounting hole on the motor.
- Rotate the motor anticlockwise around Hole 1, and align Hole 2 and Hole 3.
- Fasten 3 M8 bolts into Holes 1, 2, and 3 from the right side to the left side.
- Fasten the 3 M8 lock nuts with flat washers on the left of the frame. Tightening torque: 35 N.m.
6.3.3 Cabling
Diagram Description: A diagram illustrating the various cable connections. Connectors are labeled: A (8-pin male, drive unit), a (8-pin female, front BUS cable), B (6-pin male, drive unit), b (6-pin female, other device), C (8-pin female, drive unit), c (8-pin male, rear BUS cable), D (power male, drive unit), d (power female, battery).
Steps:
- Link the female connector (8 pin) for EB-BUS “a” to the male connector (8 pin) at the drive unit “A”.
- Link the male connector (8 pin) for EB-BUS “c” to the female connector (8 pin) at the drive unit “C”.
- Link the power connectors together.
Note: The connection of the 6-pin EB-BUS to the drive unit depends on customer functional requirements.
6.3.4 Cable Connector and Method of Using BAFANG Tool
Diagram Description: An illustration showing a cable connector and the BAFANG tool being used to secure it.
Steps:
- Hold the cable connector with your left hand.
- Insert the BAFANG tool into the bottom of the cable connector with your right hand.
- Turn the BAFANG tool clockwise to ensure a tight fit.
- Insert the unit into the corresponding position at the drive unit.
- After insertion, turn the BAFANG tool counterclockwise to release and remove it.
6.3.5 Bash Guard and Cover Installation
Diagram Description: Illustration showing the installation of a covering case using screws.
Components: A (Hexalobular socket pan head screw M3*8), B (Covering case).
Use a T10 Torx screw driver to tighten 3 M3*8 screws through the designated holes on the covering case to the frame interface. Tightening torque: 1 N.m.
Diagram Description: Illustration showing the installation of a bash guard using screws.
Components: A (Hexagonal socket head cap screw M5*8), B (Bash guard).
Use an internal hex wrench to tighten 4 M5*8 screws through the designated holes on the bash guard to the frame interface. Tightening torque: 4 N.m.
6.3.6 Chain Wheel Installation
Diagram Description: Illustration showing the chain wheel and lock ring being installed onto the drive unit's spline shaft.
Components: A (Chain wheel - may be made according to customer orders), B (Lock ring), C (BAFANG tool).
Steps:
- Place the chain wheel onto the spline shaft of the drive unit.
- Use the BAFANG tool to fasten the lock ring onto the spline shaft. Tightening torque: 35 N.m.
6.3.7 Crank Installation
Diagram Description: Illustrations showing the installation of the left and right cranks onto the drive unit's spindle.
Components: A (Left crank), B (Right crank), C (Screw M16 for the crank), D (Hexagonal socket head cap screw M6*20).
Steps:
- After mounting the right crank on the right shaft, fasten the M16 screw using the internal hex wrench. Torque: 1.5 N.m.
- Alternately fasten 2 M6*20 screws using an internal hex wrench. Note: Do not tighten screws from one side at a time. Torque: 15 N.m.
- Install the left crank in the same manner. Note: Ensure both cranks are parallel.
6.3.8 External Speed Sensor Installation
Model: SR SD021.01
Diagram Description: Illustration showing the speed sensor and magnet installation on a bicycle frame.
Components: A (Speed sensor), B (Magnet for the speed sensor).
Steps:
- Fasten the mounting screws through the speed sensor using a cross screwdriver.
- Tighten the speed sensor onto the frame.
- Place the rubber seal over the speed sensor screw. Torque requirement: 1.5 N.m - 2 N.m.
Note: Ensure the gap between the speed sensor and the magnetic unit is between 10 and 20 mm.
Model: SR SD051.02
Diagram Description: Illustration showing the speed sensor installation on a rear flat fork and the magnet installation on a disc brake.
Components: A (Rear flat fork), B (Speed sensor).
Steps:
- Place the sensor in the mounting area of the rear flat fork.
- Tighten the M5*12 countersunk head plum screw clockwise and install the plug. Torque: 3 N.m.
Diagram Description: A detailed diagram showing the magnet mounting area on a disc brake, including dimensions for the center and boundaries of the magnet.
Install the magnet on the disc brake. Use a screwdriver to tighten 2 M5*12 countersunk head plum screws. Torque: 3 N•m.
6.4 Maintenance
- Maintenance must be performed by authorized personnel using the correct equipment.
- Do not disassemble the motor.
- Do not use thinners or other solvents to clean components, as these can damage surfaces.
- Avoid submerging the unit in water to protect the components.
- Avoid using high-pressure cleaning jets.
- For prolonged storage, turn off the battery and store the unit away from heat sources.
